Weighing Systems for the Heavy Industries ABB

8/16/2019 Weighing Systems for the Heavy Industries ABB

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Robust and reliable Weighing systems for the heavy industries


2/122 | Weighing systems for the heavy industries

Online weighing systemsPrompt and accurate weighing information

High accuracy and reliability

ABB‘s many years of experience has enabled it to developweighing systems which eminently meet these requirements.

Our weighing systems, which are especially designed for

these environmental conditions, can withstand impact loads

and high overloads without a loss of accuracy.

Customized solutions

We offer a wide range of load cells and solutions for cranes

and platforms in all environments.

− Crane weighing systems

− Overload protection for cranes – load pins

− Scrap weighing systems − Torpedo-type ladle car scales

− Continuous casting plants

Ladle-, tundish and slab scales

− Blast furnace weighing systems

− Container scales

− Charging scales

− Hopper scales

− Rolling mil ls

− Roller conveyors

− Coil scales

Heavy demands are made on weighing systems for use in metal-processing and heavy industries because they are an importantcomponent in the process chain. It must be guaranteed thatall the components work safely, accurately and reliably in a harshoperating environment.

Load information available at all times

The load informat ion is immediately and cont inuously avai lablewith our weighing system without the need for any additional

operations. This means that you have a better overview of stock

and recipes with an immediate effect on material consumption

and the time taken to prepare batches.

System integration

Weighing data can also be integrated across the plant in

process data handling, warehouse and logging systems to

provide general monitoring and quality control.

Rugged design

Our weighing systems are particularly suitable for scales inharsh environmental conditions found in heavy industry. They

are highly resistant to the influences of the ambient temperature.

Special design solutions are available.


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Tried-and-tested reliable technologyFor harsh operating environments

Tried-and-tested reliable technology

− Strain gauge measurement principle

− High accuracy

− High overload capacity, up to 800%

− Wide range of measuring sensors

− Great variety of interfaces and control units

− System integration – freely programmable

Experience and Know-how

ABB has decades of experience and know-how in the field of

weighing systems and accurate and reliable measurement of

flatness, position, tensile force, thickness or torque in conti-nuous operation. The Force Measurement section of ABB is

the world’s leading supplier of advanced measuring technology

for the steel, paper and conveyor belt industries.

ABB is the right partner

Our customers can rely on ABB as a dependable partner

with industrial expertise and excellent designs.

ABB stands for:

Expertise and experience.Custom-designed solutions.

Tried-and-tested reliable technology.International references.

Feel free to contact us!



Load cellFor cranes

Mounting and installation versions

The disk-shaped load cel l is either mounted on the hook block

or the lifting beam. The load on the ropes is transmitted to a

weighing terminal via the load cell. The load cells are insensitiveto lateral forces and are fitted with strong dustproof cover

plates. After installation, the load cells are an integrated part

of the crane st ructure.

The crane scale load cell is available with various nominal

capacities depending on the required load. High temperature

compensation and high temperature cables are available as

options.

Replacement of existing load cells

The existing Pressductor® load cell type QGPK105 can be

replaced without any problems. All the mechanical dimensionsand measuring ranges are fully compatible.

The 9QGPK crane scale load cell is designed for use in cranesand for the measurement of the tensile force between thehook and the ropes. Rugged and reliable with capacities upto 160 t.

The advantages

− Suitable for harsh environmental conditions

− Mechanically rugged design

− High resistance to the influences of temperature − High accuracy



Load cellFor use in container and platform scales

Mounting and installation

The load cells are usually installed under a platform or a

weighbridge in a weighing frame. The applied load is trans-

ferred via the rubber pressure plates or sliding pressureplates to the load cells. The load cells are usually connected

to the weighing controller via a junction box.

The load cell is available with various nominal capacities

depending on the required load. Versions for high ambient

temperatures (max. +180 °C) are available as an option.

Replacement of existing load cells

The existing Pressductor® load cell type QGPL105 can be

replaced without any problems. All the mechanical dimensions

and measuring ranges are fully compatible.

The 9QGPL load cell has a especially rugged design and issuited for weighing in harsh environments. It is usually usedin conjunction with rubber/steel pressure plates or slidingpressure plates.

The advantages

− Suitable for harsh environmental conditions

− Mechanically rugged design

− High resistance to the influences of temperature − High accuracy

− Easy commissioning



Load [t] A B C D D1 D2 E F G H J K R1 R3 α°

6,3 145 180 170 400 80 16 320 16 50 15 20 80 210 15 12

10 155 205 195 450 100 20 350 20 70 20 25 100 235 20 10

16 185 215 205 500 120 20 410 20 70 20 25 100 260 20 12

25 200 270 260 600 160 24 450 20 70 20 25 100 310 25 13

40/63 250 300 290 700 200 24 550 28 90 20 30 120 360 25 13

100 265 355 340 800 240 30 590 28 120 25 40 150 410 30 15

160 295 395 380 900 280 30 650 32 120 25 40 150 460 30 17

Load cell for container and platform scales type 9QGPL

Measurement principle Strain gauge

Calibrated output 0.5 mV/V

Bridge resistance 700 Ω

Material nickel-plated steel

Calibrated temperature -30…+45 °C

max. -20…+100 °C

Safe overload 400% of FnomMax. overload 800% of F

nom

Excitation range 10 V AC/DC

Nominal excitation 15 V DC

Combined error 0.1% of Fnom

Repeat accuracy ± 0.03% of Fnom

Insulation resistance > 5000 MΩ

Capacities For loads from 5 t to 160 t

Load cells Technical data

Load [t] D1 H H1 R

5 132 160 148 19.00

10 143 175 161 25.40

16 154 185 169 31.75

25 184 195 179 31.75

40 204 230 214 31.75

63 224 255 237 38.10

100 245 270 252 38.10

160 295 310 292 38.10

Dimensions in mm

Dimensions in mm

Load cell for cranes type 9QGPK

Measurement principle Strain gauge

Calibrated output 0.5 mV/V

Bridge resistance 700 Ω

Material Nickel-plated steel

Calibrated temperature -30…+100 °C

Safe overload 250% of Fnom

Max. overload 400% of Fnom

Excitation range 5…20 V DC

Nominal excitation 15 V DC

Combined error ± 0.1% of Fnom

Repeat accuracy ± 0.02% of FnomInsulation resistance > 5000 MΩ

Capacities For loads from 6.3 t to 160 t


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Control units and operator panelsFor load cells

Typ IT1000 IT2000P IT3000A/AP/E IT8000 IT9000 IT9000E Profibox

Appl ication

Installation

Design

Display

Keyboard

Dimensions

B x H x T [mm]

Power supply

Interfaces

Software

Load display

and/or data

transfer to PLC

On-site or

control room

Wall/desktop or

panel-mounting

13-character

text display

5 keys

168 x 167 x 115

10-30 V DC or

110-240 V AC

1 scale

1 x serial

RS232/RS485 or

1 x parallel or

1 x analog

output 15 Bit

BASIC, COUNT,

FILL, CHECK,

ONLINE

Data transfer

to PLC via

PROFIBUS-DP

On-site or

control room

Only for DIN

rail mounting

16-character

LCD display

5 keys

86 x 160 x 67

12-30 V DC

1 scale

1 x PROFIBUS-DP

1 x parallel or

1 x analog

output 15 Bit

1 x serial RS485

ONLINE AP

Load display

and/or data

transfer to PLC

On-site or

control room

Wall/desktop or

panel-mounting

20-character

text display

20 keys,

alphnumeric

225 x 190 x 145

10-30 V DC or

110-240 V AC

1 or 2 scales

2 x serial

RS232/RS485

1 x parallel or

1 x analog

output 15 Bit

Options:

PROFIBUS-DP (AP)

Ethernet (E)

BASIC, COUNT,

TRUCK ONLINE,

FILL, CHECK,

ONLINE

Freely program-

mable terminal

for cran scales or

large containerscales

Operator place or

control room

Wall/desktop or

panel-mounting

4 x 20-character

text display

32 keys,

alphnumeric

260 x 210 x 170

10-30 V DC or

110-240 V AC

1 or 2 scales

3 (4) x serial

RS232/RS485

2 x parallel or

2 x analog

output 15 Bit

Options:

PROFIBUS-DP (AP)

Ethernet (E)

DeviceNet

BAG, BASIC,

BATCH,

BIGBAG, BULK,

CHECK, COUNT,

FILL,

FLOW CONTROL,

ONLINE,

TRUCK,

ABB-CRANE

Freely program-

mable terminal

for cran scales or


Operator place or

control room

Wall/desktop or

19“ housing

2 x 20-character

text display

32 keys,

alphnumeric

300 x 210 x 150483 x 132,5 x 150

10-30 V DC or

110-240 V AC

1 or 2 scales

2 (5/6) x serial

RS232/RS485

2/8 x parallel or

2/8 x analog

output 15 Bit

Options:

PROFIBUS-DP (AP)

BAG, BASIC,

BATCH,

BIGBAG, BULK,

CHECK, COUNT,

FILL,

FLOW CONTROL,

ONLINE,

TRUCK,

ABB-CRANE

Freely program-

mable terminal

for cran scales or


Operator place or

control room

Wall/desktop or

panel-mounting

8 x 44-character

TFT display

62 keys,

alphnumeric,

cursor keys

370 x 265 x 140

10-30 V DC or

110-240 V AC

1 or 2 scales

3 (5/6) x serial

RS232/RS485

2/8 x parallel or

2/8 x analog

output 15 Bit

Ethernet

Options:

PROFIBUS-DP (AP)

CAN-Bus

BAG, BATCH,

BULK, CHECK,

COUNT, FILL,

TRUCK,

ABB-CRANE

On-site device

for data transfer

to PLC

On-site

Load cell

junct ion box

-

-

325 x 107 x 64

10-30 V DC or

110-240 V AC

PROFIBUS-DP

1 x serial RS232

1 x parallel



ExamplesCustomer-specific applications

Block diagram typical crane weighing system

Block diagram for ladle turret

Load cells

9QGPK 40

Weighing controller IT9000 with IFU in operator pulpit

ADC Box

For service purpose (mandatory)

123.4

Modem set for radio

transmission

IT9000RS

485.4/

422

RS

485.4/

422

Touch screen operator panel

P I M #

1

P I M #

2

P I M #

3

Z e r o i n g f r o m P

L C

T a r e f r o m P

L C

L o c a t i o n : A f u r n a c e

L o c a t i o n : B f u r n a c e

L o c a t i o n : A . O . D .

n o t u s e d

Power supply

Cable reeler

4 x 9 Q G P

L - 6 3 w i t h Q G M T 1 0 3 - 6 3

4 x 9 Q G

P L - 6 3 w i t h Q G M T 1 0 3 - 6 3

R S 4 8 5

Load cells, side A & B

S e r v i c e / P r i n t e r

A D E

A D E

A D E

A D E

A D E

A D E

A D E

A D E

AC

DC

110 VAC

l / c # 1

l / c # 2

l / c # 3

l / c # 4

l / c # 5

l / c # 6

l / c # 7

l / c # 8

Controller IT8000S (panel mount)

ADC Box with 4 x ADM

ADC Box with 4 x ADM

S2 Box

MAI module A MAI module B

110 VAC

1 1 0 V A C

1 1 0 V A C

R S 4 8 5

Load cells



Overload detection for cranesLoad pins

High demands on the safety of cranes

For that purpose ABB has developed pin load cells and eva-

luation electronics, dedicated to indicate exceptional load

situations of the crane.

An over load system consists of a load pin, containing stra in

gauge sensors. It replaces the rope’s fixed point shaft or it can

be used instead of a shaft in any loaded sheave arrangement,

either in the hook block or on the crane’s trolley. The load

pin, working as a double shear beam, sends an output signal

to the load cell evaluation electronic, which in turn generates

an alarm signal to inform the crane operator about an over-

load situation.

Increasing demands on the safety of cranes makes it necessaryto monitor the loads applied. In case of an overload or animbalanced load situation the operator should be informedabout that event.

Tailor-made customized application

The load pin is a non-standard part, made from stainless steel,

which is tailor-made according the crane’s design. It’s designed

to fit into the available mechanics and provides a safetyfactor of at least 300%. Load pins can be rated for loads from

300 kg to 1,000 t and provide a typical error of ± 1…3% of

the nominal load.



Tailor-made and customer-specific

Evaluation electronics

The evaluation electronics are s imple designed units, to be

mounted either on a DIN rail in the control room or into a

locally installed housing. The units provide one or three alarm

outputs for overload detection (typically 110 %), slack rope

detection or detection of asymmetrical loads. All units provide

analog load output signals, 0…10 V or 4…20 mA.

The advantages

− Reliable and accurate also for harsh environmental

conditions

− Easy installation and operation − Cost-effective and efficient in operation

Technical data load pins

Design Double shear beam

Material Stainless steel

Protection class IP65, optional IP68

Typical error ± 1% of nominal load

Evaluation electronics Error ± 0.5%

Output sensitivity ± 1 mV/V ± 20%

Safety factor 300%

Load pin electronics

BRIDGE BOY 1-R and 3-R

− Load monitor with 1 to 3 relays

− Overload detection, not for weighing,

− Slack rope detection and detection of asymmetric loads

− Analogue output signal (0…10 V or 4…20 mA)

− Test function

− Input: mV/V

− 4-wire connection

− Multimeter setup

COACH DATA II − Data recording and management system for cranes

and hoisting devices, can be used as a “Black Box”

− Data logging of all hoisting movements (up, down,

transversal and directional motion) for several years

− Maintenance planning tool through SWP (Safe Working

Period) calculation

− Optional GSM module for SMS alerts, such as overloads,

SWP overdue, cut wire etc.

Bridge Boy Coach Data


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Contact us

3 B D D 0 1 6 5 4 0 - E N 0

6 . 2

0 1 1 ABB Automation GmbH

Force Measurement

Oberhausener Str. 33

40472 Ratingen, Germany

Phone: +49 2102 12-253020

Fax: +49 2102 12-1414

E-Mail: [email protected]

www.abb.com/forcemeasurement

Note:

We reserve the right to make technical changes or

modify the contents of this document without prior

notice. With regard to purchase orders, the agreed

particulars shall prevail. ABB does not accept any

responsibility whatsoever for potential errors or

possible lack of information in this document.

We reserve all rights in this document and in the

subject matter and illustrations contained therein.

Any reproduction, disc losure to third parties or

utilization of its contents – in whole or in parts – is

forbidden without prior written consent of ABB.

Copyright© 2011 ABB All rights reserved

Weighing Systems for the Heavy Industries ABB

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